Disassembly - Part 2

DISASSEMBLY PART 2 - RL4F03A & RE4F03V




35. Remove high clutch hub and needle bearing from transmission case.
36. Check high clutch hub and needle bearing for damage or wear.




37. Remove front sun gear and needle bearings from transmission case.
38. Check front sun gear and needle bearings for damage or wear.
39. Remove front planetary carrier assembly and low one-way clutch according to the following procedures.




a. Remove snap ring using a screwdriver.




b. Remove front planetary carrier with low one-way clutch.




c. Check that low one-way clutch rotates in the direction of the arrow and locks in the opposite direction.
d. Remove low one-way clutch from front planetary carrier by rotating it in the direction of unlock.




e. Remove needle bearing from front planetary carrier.




f. Check front planetary carrier, low one-way clutch and needle bearing for damage or wear.
g. Check clearance between pinion washer and planetary carrier using feeler gauge.

Standard clearance: 0.15 - 0.70 mm (0.0059 - 0.0276 in)
Allowable limit: 0.80 mm (0.0315 in)

Replace front planetary carrier if the clearance exceeds allowable limit.

40. Remove rear planetary carrier assembly and rear sun gear according to the following procedures.




a. Remove rear planetary carrier assembly from transmission case.




b. Remove rear sun gear from rear planetary carrier.




c. Remove needle bearings from rear planetary carrier assembly.




d. Check rear planetary carrier, rear sun gear and needle bearings for damage or wear.
e. Check clearance between pinion washer and rear planetary carrier using feeler gauge.

Standard clearance: 0.15 - 0.70 mm (0.0059 - 0.0276 in)
Allowable limit: 0.80 mm (0.0315 in)

Replace rear planetary carrier if the clearance exceeds allowable limit.




41. Remove rear internal gear from transmission case.




42. Remove needle bearing from rear internal gear.
43. Check needle bearing for damage or wear.




44. Remove forward clutch assembly from transmission case.




45. Remove thrust washer and bearing race (only RL4F03A) from transmission case.

RL4F03A

46. Remove output shaft, output gear and reduction gear according to the following procedures.




a. Remove side cover.
- Do not reuse side cover bolts.




b. Set manual lever to "P" position to fix idler gear and out- put gear.
c. Unlock both idler gear and output gear lock nuts using a pin punch.




d. Remove idler gear and output gear lock nuts.
- Do not reuse idler gear and output gear lock nuts.




e. Remove idler gear and output gear using a puller.




f. Remove reduction gear and output shaft.
g. Remove adjusting shim from reduction gear.
h. Remove adjusting spacer from output shaft.

RE4F03V

46. Remove output shaft assembly according to the following procedures.




a. Remove side cover bolts.




b. Remove side cover by lightly tapping it with a soft hammer.
- Be careful not to drop output shaft assembly as output shaft assembly may be removed together with side cover.




c. Remove adjusting shim.




d. Remove output shaft assembly.




- if output shaft assembly was removed together with side cover, remove side cover by tapping it lightly with a soft hammer.




e. Remove needle bearing.

47. Disassemble reduction gear according to the following procedures.




a. Set manual shaft to position "P" to fix idler gear.
b. Unlock idler gear lock nut using a pin punch.




c. Remove idler gear lock nut.
- Do not reuse idler gear lock nut.




d. Remove idler gear with puller.




e. Remove reduction gear.
f. Remove adjusting shim from reduction gear.

RL4F03A & RE4F03V




48. Remove return spring from parking shaft using a screwdriver.




49. Draw out parking shaft and remove parking pole from transmission case.
50. Check parking pole and shaft for damage or wear.




51. Remove parking actuator support from transmission case.
52. Check parking actuator support for damage or wear.

RL4F03A only
53. Remove governor valve assembly according to the following procedures.




a. Remove snap ring using a screwdriver.




b. Remove spacer from governor cap.




c. Remove governor cap using water pump pliers.
d. Remove O-ring from governor cap.




e. Remove governor valve assembly.




f. With low primary weight closed, place top of governor valve assembly down to make sure governor valve properly lowers under its own weight.
g. Place top of governor assembly down. Operate both low and high secondary weights to make sure governor valve functions properly.

RE4F03V only




54. Remove revolution sensor from transmission case.